Perimeter resin feeding of composite structures

Claim 1

A method of forming a solid fiber reinforced hollow structure having irregular cross sectional areas comprising the steps of: (a) providing a mold having upper and lower pieces with one of said pieces including a first plurality of resin channels for receiving resin; (b) placing different areas of layers of fibrous material of said irregular cross sectional areas along the inner walls of said upper and lower pieces directed adjacent said first plurality of resin channels; (c) placing an inflatible member within said fibrous material between said layers of fibrous material in said upper and lower mold pieces; (d) closing said mold pieces; (e) inflating said inflatible member; (f) providing a plurality of inlet ports connected to said first channels with at least one inlet port being provided for each channel; (g) injecting resin through said plurality of inlet ports into said first resin channels and then directly into the different areas of said fibrous material; (h) providing a plurality of air vent channels directly adjacent said fibrous material with air port vents connected thereto with at least one air vent channel being provided for each of said inlet ports in said first plurality of resin channels, and (i) curing said fibrous material to form said solid fiber reinforced structure, whereby said plurality of inlet ports and air vents permit relatively fast resin injection to form said solid fiber structure.

Claim 2

A method of forming a solid fiber reinforced hollow structure having irregular cross sectional areas comprising the steps of: (a) providing a mold having upper and lower pieces with one of said pieces including a first plurality of resin channels for receiving resin; (b) placing different areas of layers of fibrous material of said irregular cross sectional areas along the inner walls of said upper and lower pieces directed adjacent said first plurality of resin channels; (c) placing an inflatible member within said fibrous material between said layers of fibrous material in said upper and lower mold pieces; (d) closing said mold pieces; (e) inflating said inflatible member; (f) providing a plurality of inlet ports connected to said first channels with at least one inlet port being provided for each channel; (g) injecting resin through said plurality of inlet ports into said first resin channels and then directly into the different areas of said fibrous material; (h) providing a plurality of air vent channels directly adjacent said fibrous material with air port vents connected thereto with at least one air vent channel being provided for each of said inlet ports in said first plurality of resin channels, and (i) curing said fibrous material to form said solid fiber reinforced structure, whereby said plurality of inlet ports and air vents permit relatively fast resin injection to form said solid fiber structure.